Disassembly And Assembly: Disassembly

CAUTION:

Do not disassemble parts other than those described in this volume.

Remove the transfer from the transaxle. < W6AJ >
Remove the RR roll stopper bracket and FR roll stopper bracket from the transaxle.
Remove the harness bracket from the transaxle.
Remove the oil filler tube and oil level gage from the transaxle.
Remove the control cable bracket and breather hose from the transaxle.
Remove the torque converter from the transaxle.

Fig 1: Removing Torque Converter From Transaxle
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the vehicle speed sensor from the transaxle case.
Remove the O-ring from the vehicle speed sensor.

Fig 2: Identifying O-Ring And Vehicle Speed Sensor
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the turbine sensor from the transaxle case.
Remove the O-ring from the turbine sensor.

Fig 3: Identifying Turbine Sensor O-Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the Park/neutral position switch.

Fig 4: Identifying Park / Neutral Position Switch
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the fluid water-cooled cooler from the transaxle case.

Fig 5: Identifying Fluid Water Cooled Cooler
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the O-ring from the fluid water-cooled cooler.

Fig 6: Identifying Fluid Water-Cooled Cooler O-Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the pressure test port bolt from the transaxle case.
Remove the O-ring from the pressure test port bolt.

Fig 7: Identifying Pressure Test Port Bolt
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the baffle plate from the converter housing.
Remove the O-ring from the baffle plate.

Fig 8: Identifying Baffle Plate O-Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove stud bolts from the transaxle case.

Fig 9: Identifying Transaxle Case Stud Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the cooler tube (IN) from the side cover.

Fig 10: Identifying Cooler Tube
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Remove the cooler tube (OUT) from the side cover.

Fig 11: Identifying Cooler Tube (OUT)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Be careful not to break the terminal body.
Remove the snap ring from the terminal body and push the terminal body into the transaxle case.

Fig 12: Identifying Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the control valve cover from the transaxle case.
IDENTIFYING BOLTS

No. of bolts 16

Fig 13: Identifying Control Valve Cover Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the control valve cover gasket from the transaxle case.

Fig 14: Identifying Control Valve Cover Gasket
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
CAUTION:
- Mounting bolt A is a hexagon head bolt.
- Mounting bolt B is a hexagon socket head bolt.

Remove control valve assembly mounting bolts A and B.

IDENTIFYING BOLTS

Bolt code	A	B
Shank length mm (in)	70.1 (2.76)	50.8 (2.00)
No. of bolts	5	4

Fig 15: Identifying Control Valve Assembly Mounting Bolts

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Remove the control valve assembly by pulling it straight.

Remove the control valve assembly from the transaxle case.

Fig 16: Identifying Control Valve Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Be careful not to drop the manual valve.
Remove the manual valve from the control valve.

Fig 17: Identifying Manual Valve
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the oil temperature sensor and bracket from the control valve.
Remove the bracket from the oil temperature sensor.

Fig 18: Identifying Oil Temperature Sensor
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the terminal assembly from the control valve.

Fig 19: Identifying Terminal Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the detent spring.

Fig 20: Identifying Detent Spring
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Remove lip seals from the transaxle case.

Fig 21: Identifying Lip Seals
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Do not damage the manual shaft oil seal mounting surface of the transaxle case when removing the manual shaft oil seal.
Using a flat-head screwdriver or equivalent, remove the manual shaft oil seal from the transaxle case.

Fig 22: Identifying Manual Shaft Oil Seal
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the ATF adjusting bolt from the transaxle case.
Remove the O-ring from the ATF adjusting bolt.

Fig 23: Identifying O-Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Mounting bolts are Torx E20 bolts.
Remove converter housing mounting bolts.
IDENTIFYING BOLTS

No. of bolts 19

Fig 24: Identifying Converter Housing Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Lightly tap the converter housing with a plastic hammer or equivalent to remove.

Fig 25: Identifying Converter Housing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Do not damage the converter housing when removing the side oil seal.
Remove the side oil seal from the converter housing using a pin punch or equivalent. < F6AJ >

Fig 26: Removing Side Oil Seal
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
(MB992195) remove the outer race of the reduction gear bearing from the converter housing.
- Slid hammer puller (MB992039)
- Slide hammer (MB990590)
  
  Fig 27: Identifying Slid Hammer Puller And Slid Hammer
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the reduction gear taper bearing shim from the converter housing.

Fig 28: Identifying Reduction Gear Taper Bearing Shim
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Using the Special Tool, remove the outer race of the differential side bearing from the converter housing.
- Slid hammer puller (MB992039)
- Slide hammer (MB990590)
  
  Fig 29: Identifying Slid Hammer Puller And Slid Hammer
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the differential taper bearing shim from the converter housing.

Fig 30: Identifying Differential Taper Bearing Shim
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the O-ring from the input shaft.

Fig 31: Identifying Input Shaft O-Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the oil pump assembly and oil strainer as one unit.
IDENTIFYING BOLTS

No. of bolts 7

Fig 32: Identifying Oil Pump Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the oil strainer from the oil pump assembly.
IDENTIFYING BOLTS

No. of bolts 3

Fig 33: Identifying Oil Strainer
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the magnet from the oil strainer.

Fig 34: Identifying Magnet
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the O-ring from the transaxle case.

Fig 35: Identifying O-Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the input shaft.

Fig 36: Identifying Input Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the bearing race and needle bearing from the 3-5 reverse clutch drum.

Fig 37: Identifying Bearing Race And Needle Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the 3-5 reverse clutch assembly.

Fig 38: Identifying Reverse Clutch Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the needle bearing from the FR sun gear.

Fig 39: Identifying Needle Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the FR sun gear.

Fig 40: Identifying FR Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the needle bearing from the FR sun gear.

Fig 41: Identifying Needle Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the FR internal gear and FR carrier as one unit.

Fig 42: Identifying FR Internal Gear And FR Carrier
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the FR internal gear and needle bearing from the FR carrier.

Fig 43: Identifying FR Internal Gear And Needle Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the low clutch assembly.

Fig 44: Identifying Low Clutch Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the thrust washer from the drum support.

Fig 45: Identifying Thrust Washer
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the differential assembly.

Fig 46: Identifying Differential Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the parking plate.

Fig 47: Identifying Parking Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the return spring.

Fig 48: Identifying Return Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the parking shaft.

Fig 49: Identifying Parking Shaft
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the parking pawl.

Fig 50: Identifying Parking Pawl
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the reduction gear lubrication tube.

Fig 51: Identifying Reduction Gear Lubrication Tube
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the reduction gear assembly.

Fig 52: Identifying Reduction Gear Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Mounting bolts are Torx E16 bolts.
Remove the side cover.
IDENTIFYING BOLTS

No. of bolts 14

Fig 53: Identifying Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the spacer and needle bearing from the side cover.

Fig 54: Identifying Spacer And Needle Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the O-ring from the transaxle case.

Fig 55: Identifying Transaxle Case O-Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the high clutch assembly.

Fig 56: Identifying High Clutch Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the reduction sun gear.

Fig 57: Identifying Reduction Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the reduction carrier.

Fig 58: Identifying Reduction Carrier
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the needle bearing from the reduction internal gear.

Fig 59: Identifying Needle Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the reduction internal gear from the high clutch hub.

Fig 60: Identifying Reduction Internal Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the needle bearing from the reduction internal gear.

Fig 61: Identifying Needle Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the high clutch hub.

Fig 62: Identifying High Clutch Hub
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the needle bearing from the RR sun gear on the rear side.

Fig 63: Identifying Needle Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the RR sun gear on the rear side.

Fig 64: Identifying RR Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the needle bearing from the RR carrier assembly.

Fig 65: Identifying Needle Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Check the plates for damage, deformation, surface burn or permanent strain. If faulty, replace.
Remove the 2-6 brake retaining plate, drive plate and driven plate from the transaxle case.

Fig 66: Identifying Brake Retaining Plate, Drive Plate And Driven Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Using a flat-head screwdriver or equivalent, remove the snap ring.

Fig 67: Identifying Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the one-way clutch and RR carrier assembly as one unit.

Fig 68: Identifying One-Way Clutch And RR Carrier Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Separate the one-way clutch and RR carrier assembly.

Fig 69: One-way Clutch And RR Carrier Assembly
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the needle bearing from the RR carrier assembly.

Fig 70: Identifying Needle Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Using a flat-head screwdriver or equivalent, remove the snap ring.

Fig 71: Identifying Snap Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Check the plates for damage, deformation, surface burn or permanent strain. If faulty, replace.
Remove the low-reverse brake retaining plate, drive plate and driven plate.

Fig 72: Identifying Low-Reverse Brake Retaining Plate, Drive Plate And Driven Plate
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the RR sun gear on the front side.

Fig 73: Identifying RR Sun Gear
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the bearing race from the RR sun gear on the front side.

Fig 74: Identifying Bearing Race
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the needle bearing.

Fig 75: Identifying Needle Bearing
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Using the Special Tool, spring compressor (MB992195) remove the snap ring.

Fig 76: Identifying Spring Compressor
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the diaphragm spring retainer.

Fig 77: Identifying Diaphragm Spring Retainer
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the diaphragm spring.

Fig 78: Identifying Diaphragm Spring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Do not feed air abruptly. Otherwise, the low-reverse brake piston may become stuck in the clutch drum.
Feed air through the oil hole as indicated in the illustration to remove the low-reverse brake piston from the transaxle case.

Fig 79: Identifying Low-Reverse Brake Piston
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove D-rings from the low-reverse brake piston.

Fig 80: Identifying D-Rings
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Mounting bolts are Torx E18 bolts.
Remove the Output gear set.
IDENTIFYING BOLTS

No. of bolts 10

Fig 81: Identifying Mounting Bolts
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Remove the O-ring from the transaxle case.

Fig 82: Identifying O-Ring
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

CAUTION: Do not damage the transaxle case when removing the side oil seal.
Using a flat-head screwdriver or equivalent, remove the side oil seal from the transaxle case.

Fig 83: Identifying Side Oil Seal
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Using the Special Tool, remove the outer race of the reduction gear bearing from the transaxle case equivalent.
- Slid hammer puller (MB992039)
- Slide hammer (MB990590)
  
  Fig 84: Identifying Slid Hammer Puller And Slide Hammer
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Using the Special Tool, remove the outer race of the differential side bearing from the transaxle case.
- Slid hammer puller (MB992039)
- Slide hammer (MB990590)
  
  Fig 85: Identifying Slid Hammer Puller And Slide Hammer
  Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.